Ultramax Refrigerated Compressed Air Dryers
Brochure & Technical Data
IP54
AUSTRALIAN TOUGH
Designed & Built for Harsh Australian
Conditions
TREATMENT PACKAGES (Dryers | Filters | Water Separators)
ELEMENTS
QUICK CHANGE
T: 08 9458 4477 - [email protected]
LABOUR SAVING
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RFD Dryer Series
DESCRIPTION
Designed and built tough for Australian Conditions, Ultramax offers the RFD Digital Cycling Refrigerated Compressed Air Dryer Treatment Packages. These treatment packages include a host of innovative design features focused on efficiency, durability and quick maintenance.
Advantages and Features:Ultramax provides a whole range of products for filtration and air purification applications with a cost effective price;
RFD SERIES - BUILT FOR AUSTRALIAN HARSH CONDITIONS
Key to the design of RFD Series is its use of environmentally friendly R134a refrigerant gas, making it suitable for low and high temperature applications whilst retaining excellent thermodynamic properties. Additionally operating at consistently lower pressures aids in increasing the compressors lifespan and reduces daily wear and tear. Innovative engineering solutions have also resulted in extra power being added to the heat exchangers, a no loss insulation system and constant dewpoint at all flow ranges. Using the R-134a refrigerants also allows our units to operate within high ambient temperature environments making them ideal for Australia’s demanding conditions.
¡ Designed for Harsh Australian Conditions. The RFD Dryers easily run with rated flows at 60 C° (maximum inlet temperature) and 50 C° (ambient temperature)
¡ Energy saving – true green product
¡ 3-in-1 heat exchanger
¡ High efficiency compressors
¡ Globally marketable refrigerant R-134a
¡ Standard electronic timer drains for 10 scfm and above
¡ Refrigerant analyzer indicator
¡ Fan cycle switch
¡ Easy removable side panels and parts
¡ Consistent dew point performance
¡ Low power consumption
¡ Low pressure drop
¡ Insulated heat exchanger
¡ Evaporator with multi-stage separator stainless steel demister
¡ High quality fan motors
¡ Oversized condenser
¡ Ideal for breathing air applications
AUSTRALIAN TOUGH
Designed & Built for Harsh Australian
Conditions
STREAMLINED WIRING & ELECTRICAL PROTECTION
Quick and easy access to the dryer internals is a key design feature of the Ultramax RFD Series dryers. RFD-1110 and larger dryers include a unique electrical box which can be accessed from the outside via an access panel. This makes it easy to access the electrical controls for installation set-up and service. All of the Ultramax RFD Series dryers are rated to IP54 standard which means the electrical controls are protected from limited dust and water spray from any direction.
Built to Australian
Specification and
Australian Conditions
Key Features
IP54
WHY USE R-134A REFRIGERANT GAS?
All Ultramax refrigerant dryers use R-134a refrigerant, offering the following host of features:
¡ Does not deplete ozone
¡ Thermodynamic properties similar to R-12 (dichlorodifluoromethane)
¡ 100% chlorine free
¡ Environmentally Friendly
¡ Completely inert
¡ High and low temperature refrigerant
¡ Operates at nearly half the pressure of other refrigerants, so the compressor life span will increase.
¡ R-134a makes the refrigerated dryer much more tolerant to adverse conditions such as high ambient temperature.
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Key Features
ALL-IN-ONE
INBUILT FILTERS & COMPACT DESIGN
Ultramax Refrigerated Air Dryers are suitable for some of the smallest of installation spaces. This is due to having two integrated filters housings built directly into the dryer frame, offering a huge advantage in not only space efficiency but also in terms of service times as well. With filters coming pre-installed upon arrival, both labour and piping costs are greatly reduced during the installation process. This compact design offers further benefits in terms of placement flexibility onsite and increased economy during transport and shipping.
QUICK-CARTRIDGE SYSTEM
Key to the Ultramax RFD Dryers success is the unique “Quick-Change” filter system. Drawing on the feed back of a host of experienced field engineers and service technicians, our design engineers have created a industry first, service friendly, zero clearance design that allows maintenance to be undertaken in only a couple of minutes by streamlining installation fixtures and mounts. Our tie-rod free, quick-fit design allows replacement filters to be easily slotted in and resealed in a fraction of the time of a traditional system.
Ultramax RFD Dryer units come with compressed air filter kits already pre-fitted. Each kit contains a filter with a X Element (coalescing filter for particulate removal) used for up to 1 micron particles alongside another with a Y Element (coalescing filter for oil removal), used to remove oil down to 0.01 ppm. As these kits are pre-fitted, onsite installation and additional, hidden filter costs normally associated with traditional Dryers are minimised.
When comparing a traditional dryer, filter and bypass system (above) to a system built around an Ultramax RFD Series Dryer (below), the gains in space efficiency and the savings in cost and time not spent on installation and fittings becomes
obvious. By incorporating the filter housings within the dryer body itself and utilising a “Quick-Cartridge” element replacement system, Ultramax RFD Series Dryers offer excellent performance in an efficient, convenient and compact package.
%Compact & Space Saving Design
Save Up 50% On Traditional Installation Times
Quick-Change Filter Element Replacement
Traditional Dryer System
Ultramax RFD Compressed Air Treatment System
Ultramax RFD Dryer System
Traditional Dryer System
Inline Filter Housings
By-Pass Valves
Air Receiver
Air Receiver
Oil / Water Separator
Oil / Water Separator
Internal View
ELEMENTS
QUICK CHANGE
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RFD Dryer Series
ULTRAMAX QUICK FIT BYPASS SETS
Our pre-made by-pass sets make an ideal addition to your dryer installation. These sets allow for quick by-passing of the dryer during servicing and filter change outs for no interruption or shutting down of the entire compressed air system for no delay in your air supply to production. As an “off the shelf” item, these sets help by lowering initial costs and time spent on installation. Simply order your set from the table below to suit your dryer.
Key Features
HOW REFRIGERATED CYCLING DRYERS WORKS
Hot saturated air from the after-cooler enters the air-to-air heat exchanger, where the air is pre-cooled by the cold, dry air leaving the heat exchanger. The pre-cooled air then enters the air/glycol heat exchanger where it is cooled to its final dew point by chilled water/glycol, flowing in the counter-current direction through the shell. The chilled air passes through the moisture separator, which has a high efficiency of separation at different flow rates. Condensate is removed from the using a timed drain valve. Finally, the cold, dry air is reheated in the air-to-air heat exchanger by the incoming hot air for maximum volumetric efficiency before exiting the dryer.
The water/glycol is chilled by a cycling refrigeration system and continuously pumped through the shell side of the air/glycol heat exchanger. The glycol flow rate remains constant, regardless of compressed air load. The refrigeration compressor unloads/or cycles OFF when pre-set temperature is reached for water/ glycol, thus minimizing electrical power consumption.
PART NUMBER* SUITS DRYER MODEL DIMENSION A
RFD18-42-BPSETRFD-18
117RFD-30RFD-42
RFD66-130-BPSETRFD-66
151RFD-96RFD-130
RFD168-300-BPSETRFD-168
193RFD-240RFD-300
RFD396-498-BPSETRFD-396
290RFD-498
RFD660-870-BPSETRFD-660
382RFD-870
Hot Refrigerant
Refrigerant Water/Glycol Hot Air Cool Air
Chilled Mixture Hot Air Cooled Air
Cooled Refrigerant Warm Mixture Pre-cooled Reheated Air Cooled Dry Air
Air Outlet
Pre-Cooler Re-Heater
Moisture Separator
Solenoid ValveDefroster
Condenser
Compressor SactonAccumulator
Air-to-Water/Glycol Heat Exchanger
Evaporator
Isolation Valve
PumpCold Bank
Storage
Air Inlet
Brass AllthreadCut To Length
Nickel PlatedBrass Ball Valve
Brass HexNipple
Brass FemaleTee
Brass UnionMale/Female
Dimension A
Brass AllthreadCut To Length
Nickel PlatedBrass Ball Valve
Brass HexNipple
Brass FemaleTee
Brass UnionMale/Female
Dimension A
TYPE A TYPE B
PLEASE NOTE: When selecting a model, be sure to specify A or B after the model number for the required type. E.g. RFD18-42-BPSET Type A has a part number of RFD18-42-BPSETA
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Key Features
PRESSURE DROP ALARM SENSOR
Keeping any compressed air system at optimum operating conditions is vital to any production process. The in-built differential pressure sensor actively monitors the difference in pressure across the pre filter and provides an audible alarm if a high pressure drop is measured when the filter reaches maximum dirt holding capacity. The filter elements can then be changed ensuring no down time and delay in your production, saving you time and money.
GROOVED COUPLINGS & FITTINGS
Designed with quick and easy service in mind, grooved couplings and fittings offer increased connection flexibility and durability, allowing service technicians to dismantle and assemble piping efficiently.
FILTER AUTO CONDENSATE DRAINS
Ultramax RFD Dryers include drain tubes connected to both the water separator’s timed solenoid drain and the in-line filters housings. These tubes are connected together into one drain tube that exits the cabinet. This tube can then easily be connected to a central condensate drain tubing network or point of disposal, removing the need for traditional extensive draining lines and time consuming installation.
PRESSURE DROPSENSOR WITH
BUZZER ALARMFOR REPLACING
ELEMENT
ENERGY SAVING DEVICE (ESD) - LOWER OPERATING COSTS
All Ultramax RFD Dryer units come equipped with a Digital Controller and Energy Saving Device (ESD) which boasts a host of economy features and alarm capabilities, resulting in highly efficient and consistent dryer solution for compressed air applications. Alongside aiding in reducing energy consumption by adjusting compressor output in real time. The ESD feature helps service techs to monitor many useful parameters and readings, greatly aiding in troubleshooting and problem solving, ultimately improving service efficiency and turnaround times.
ESD units allow Ultramax RFD Dryers to continue functioning without the need for compressed air to be moving through the system and offer autonomous shut-down features suitable for weekends, nights and holidays. This greatly reduces running costs by simply shutting down the dryer automatically when it is not in use.
DANFOSS REFRIGERATION CONTROLS
Ultramax RFD Series dryers make use of industry leading Danfoss Refrigeration controls. Based in Denmark and with over 80 years of innovative experience, Danfoss produces high quality components, sub-assemblies and integrated solutions for air compressors, refrigerant and absorption dryers for the compressed air industry and provides the Ultramax RFD Series Dryers range with efficient, high quality and reliable controls.
SPARE PARTS & SERVICE
Ultramax stocks an extensive range of spare parts for our full host of RFD Dryers, which when combined with our strong support and service network, ensures our Dryers are able to operate at their best and if any issue should occur, it can be addressed easy and efficiently, minimising any on-site delays.
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RFD Dryer Series Key Features
COMPREHENSIVE CONTROLS
Advanced, User-Friendly Microprocessor Controls Models RFD-1110 and larger dryers include an ESD-3 SMART controller:
REMOTE MONITORING CAPABILITIES (OPTIONAL)
The Ultramax controller has a communications interface that can be used for remotely monitoring. Modbus RTU protocol is used for communication. The user can remotely start the dryer, stop the dryer, reset any alarm and monitor:
MODELS RFD-18 TO RFD-870 USE AN ESD1
ELECTRO-MECHANICAL CONTROLLER.
The Ultramax controller has a communications interface that can be used for remote monitoring. Modbus RTU protocol is used for communication. The user can remotely start the dryer, stop the dryer, reset any alarm and monitor:
¡ Digital multi-functional display
¡ Digital dew point temperature read-out for an accurate indication of actual working conditions
¡ Multiple alarm safety with easy-to-understand coded messages
¡ Extensive programmability allows system to be personalized to individual user needs
¡ Status reports for quick reference to dryer operation
¡ Indicator to optimize preventive maintenance
¡ Volt-free alarm contact offers a remote status signal
¡ The controller has 8 temperature sensor inputs
¡ Evaporator temperature
¡ Inlet air temperature
¡ Ambient temperature
¡ Refrigerant gas high and low temperature
¡ Fan, compressor and condenser working conditions
¡ Dew point
¡ Drain function
¡ Working hours
¡ Dew point indicator: Located on the control panel, displays dew point reading
¡ Energy Saving Device: (ESD) This device helps dryer save energy when there is not any compressed air flow through the dryer.
¡ Filter change alarm on the front panel
¡ Remote Stop/Start
¡ Remote Alarm Voltage Free Contacts - Normally Open
Operator Configuration
Buttons
Economy Mode
Power ON
Drain Outlet Control
Power OFF
Alarm Reset
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Key Features Technical Details
SCROLL COMPRESSORS
Selected specifically for their strength against liquid shock and high-energy efficiency, Scroll Compressors are an ideal choice for the RFD Range of Dryer as they offer a compact, quiet and low-maintenance solution.
PLEASE NOTE: Industry best practice of shielding units from direct heat and weathering should be adopted to prevent excessive exposure and increase the longevity of the unit and its components.
EASY ACCESS
Cooling components are quickly and easily accessed via the screw free panels and plastic handles located around the unit. Simply unclip the panels in one easy action to change filters and preform other maintenance activities.
The dryers are equipped with a compact Mono-Bloc Heat Exchanger module. This assembly has been specially designed to dry compressed air and includes the following key features:
¡ Very low pressure drop
¡ A centrifugal condensate separator for high efficiency condensate removal and requiring no maintenance.
¡ Rust free for very long service life
ALUMINIUM PLATE HEAT EXCHANGERMODEL LENGTH (mm) WIDTH (mm) HEIGHT (mm) WEIGHT (Kg)
RFD-18 413 363 557 32RFD-30 413 363 557 32RFD-42 413 363 557 32RFD-66 473 453 832 51RFD-96 473 453 832 53RFD-130 473 453 832 55RFD-168 553 503 874 78RFD-240 553 503 874 83RFD-300 553 503 874 86RFD-396 678 648 1157 160RFD-498 678 648 1157 165RFD-660 948 728 1370 220RFD-870 948 728 1370 230RFD-1110 948 798 1460 270RFD-1380 948 798 1460 285RFD-1710 1163 778 1725 392RFD-2220 1163 778 1725 410RFD-2664 1397 847 1770 492RFD-3132 1397 847 1770 520RFD-4068 1467 1077 1930 696RFD-4680 1467 1077 1930 718RFD-5580 2188 1062 1925 900RFD-6300 2188 1062 1925 -RFD-7200 2697 897 1975 -RFD-8400 2697 897 1975 -RFD-10000 2550 1550 2100 1600
SUPERHEAT OF THERMOSTATIC
EXPANSION VALVE
EVAPORATING PRESSURE
FANPRESSURE
SWITCH
SECURITY HIGH
PRESSURE SWITCH
SECURITY LOW
PRESSURE SWITCH
DRAINTIMER
REFRIGERANTTEMPERATURE
SWITCH
WATER FLOWVALVE
(IF WATERCONDENSER)
5°C - 10°C 2.05 bar 9 -12 bar 25 bar 1.6 bar 32 45°C 11 bar
DIMENSIONS
PRESSURE & TEMPERATURE
The following details apply to all RFD dryer models
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EXAMPLE FOR CHOOSING THE CORRECT DRYER If a compressor delivers 200 m3/h at 6 bar the dryer inlet temperature is 40°C and ambient temperature is 30°C. Please choose your Dryer as follows; 200 / 0.94 / 0.92 / 0.98 = 236 m3/h - The correct Dryer for this application is RFD240.
CORRECTION FACTORS FOR RFD AIR DRYERSINLET TEMPERATURE °C 30 35 40 45 50 60 - -
F1 1.29 1 0.92 0.78 0.65 0.45 - -
AMBIENT TEMPERATURE °C 20 25 30 35 40 50 - -
F2 1.05 1 0.98 0.93 0.84 0.7 - -
PRESSURE BAR 4 6 7 8 10 12 14 16
F3 0.80 0.94 1 1.04 1.11 1.16 1.22 1.25
MODEL CAPACITY (m3/h)
Dryer Capacity
(cfm)POWER CONNECTION
SIZE FILTER QUANTITY & TYPE ELEMENT TYPE
PRESSURE DROP (mbar)
CONTROL TYPE
NOMINAL PRESSURE
(bar)
MAX. WORKING
PRESSURE (bar)
MIN. / MAX. AMBIENT TEMP °C
MAX. INLET
TEMP. °C
RFD-18 18 11 230/1/50 ½” 1 G50MMX + 1 G50Y M50 KIT 100 ESD-1 7 16 4 / 50 60RFD-30 30 18 230/1/50 ½” 1 G50MX + 1 G50Y M50 KIT 140 ESD-1 7 16 4 / 50 60RFD-42 42 25 230/1/50 ½” 1 G50MX + 1 G50Y M50 KIT 220 ESD-1 7 16 4 / 50 60RFD-66 66 39 230/1/50 ¾” 1 G150MX + 1 G150Y M150 KIT 50 ESD-1 7 16 4 / 50 60RFD-96 96 56 230/1/50 ¾” 1 G150MX + 1 G150Y M150 KIT 100 ESD-1 7 16 4 / 50 60RFD-130 130 77 230/1/50 ¾” 1 G150MX + 1 G150Y M150 KIT 150 ESD-1 7 16 4 / 50 60RFD-168 168 99 230/1/50 1½” 1 G500MX + 1 G500Y M500 KIT 100 ESD-1 7 16 4 / 50 60RFD-240 240 141 230/1/50 1½” 1 G500MX + 1 G500Y M500 KIT 150 ESD-1 7 16 4 / 50 60RFD-300 300 177 230/1/50 1½” 1 G500MX + 1 G500Y M500 KIT 80 ESD-1 7 16 4 / 50 60RFD-396 396 233 230/1/50 2” 1 G851MX + 1 G851Y M851 KIT 120 ESD-1 7 16 4 / 50 60RFD-498 498 293 230/1/50 2” 1 G1210MX + 1 G1210Y M1210 KIT 100 ESD-1 7 16 4 / 50 60RFD-660 660 388 230/1/50 2” 1 G1210MX + 1 G1210Y M1210 KIT 100 ESD-1 7 16 4 / 50 60RFD-870 870 512 230/1/50 2” 1 G1210MX + 1 G1210Y M1210 KIT 120 ESD-1 7 16 4 / 50 60RFD-1110 1110 653 400/3/50 3” 1 G1820MX + 1 G1820Y M1820 KIT 220 ESD-3 7 16 4 / 50 60RFD-1380 1380 812 400/3/50 3” 1 G1820MX + 1 G1820Y M1820 KIT 180 ESD-3 7 16 4 / 50 60RFD-1710 1710 1006 400/3/50 3” 1 G2700MX + 1 G2700Y M2700 KIT 120 ESD-3 7 16 4 / 50 60RFD-2220 2220 1306 400/3/50 3” 1 G2700MX + 1 G2700Y M2700 KIT 220 ESD-3 7 16 4 / 50 60RFD-2664 2664 1568 400/3/50 DN100 Not Included Not Included 170 ESD-3 7 16 4 / 50 60RFD-3132 3132 1843 400/3/50 DN100 Not Included Not Included 250 ESD-3 7 16 4 / 50 60RFD-4068 4068 2394 400/3/50 DN100 Not Included Not Included 200 ESD-3 7 16 4 / 50 60RFD-4680 4680 2754 400/3/50 DN100 Not Included Not Included 220 ESD-3 7 16 4 / 50 60RFD-5580 5580 3284 400/3/50 DN150 Not Included Not Included 200 ESD-3 7 16 4 / 50 60RFD-6300 6300 3708 400/3/50 DN150 Not Included Not Included 230 ESD-3 7 16 4 / 50 60RFD-7200 7200 4237 400/3/50 DN150 Not Included Not Included 220 ESD-3 7 16 4 / 50 60RFD-8400 8400 4943 400/3/50 DN200 Not Included Not Included 220 ESD-3 7 16 4 / 50 60RFD-10000 10000 5885 400/3/50 DN200 Not Included Not Included 220 ESD-3 7 16 4 / 50 60
RFD DRYER TECHNICAL SPECIFICATIONS
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Ultramax Master Catalogue
PLEASE NOTE: Inbuilt filter option not available on all models. External filter elements available - sold separately.
[email protected] Perth tel: 08 9458 4477 Ultramax Systemswww.ultramax.net.au fax: 08 9458 4470 31 Morgan Street Cannington Western Australia 6107
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¡ Honesty and fairness in the way we interact.
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